CN110177644B - 超声波接合用工具和超声波接合方法 - Google Patents

超声波接合用工具和超声波接合方法 Download PDF

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CN110177644B
CN110177644B CN201680091685.2A CN201680091685A CN110177644B CN 110177644 B CN110177644 B CN 110177644B CN 201680091685 A CN201680091685 A CN 201680091685A CN 110177644 B CN110177644 B CN 110177644B
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ultrasonic bonding
tool
synthetic resin
horn
layer
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CN110177644A (zh
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中野孝洋
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Vision Aesc Japan Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8223—Peel tests
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
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    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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Abstract

在超声波接合装置(21)的变幅杆(23)侧设有有规律地形成有多个凸部(31)的头(24)。各凸部(31)呈具有4个侧面(31a、31b、31c、31d)和平坦的顶面(31e)的正四棱锥形状。彼此相对的两个侧面所成的顶角(α)比90°大，例如是120°。在将电池单元的两张隔板(1)接合了时，隔板(1)粘附于凸部(31)的力变弱，而不会附着于变幅杆(23)。

Description

超声波接合用工具和超声波接合方法
技术领域
本发明涉及一种具备在将合成树脂制片重叠而接合的超声波接合装置的变幅杆侧或者砧座侧所使用的凸部的超声波接合用工具的改良。
背景技术
在专利文献1中公开有如下内容：作为锂离子二次电池那样的层叠型电池中的正极·负极间的隔板，使用在聚丙烯等合成树脂层的一个面设有由陶瓷粒子构成的耐热层的片状的隔板，且设为一个电极例如正极夹在两张隔板之间的状态，而通过将隔板的周缘接合，从而构成所谓的袋装电极。
夹着正极的两张隔板以各自的耐热层相互面对的方式配置，并在周缘的多个部位处加热接合而成为袋状的隔板。在此，若由陶瓷粒子构成的耐热层介入，则合成树脂层的热熔接变得困难，因此，在专利文献1中，在隔板的周缘设置使陶瓷等耐热材料为零或者使陶瓷等耐热材料减少了的无耐热层部，对该无耐热层部彼此进行加热接合。
如此，在对具有耐热层的隔板彼此进行加热接合的方法中，需要形成无耐热层部。
另一方面，若将在层叠型电池的制造中普遍用于电极引板与正极·负极的集电体之间的接合的超声波接合适用到上述那样的片状隔板的接合，则存在如下问题：熔融后的树脂材料粘附于在变幅杆和砧座中的至少一者设置的滚花状的凸部。
现有技术文献
专利文献
专利文献1：国际公开第2014/058001号
专利文献2：日本特开2009-78452号公报
发明内容
本发明的超声波接合用工具排列有多个凸部，该凸部呈具有平坦的顶面的四棱锥形状，各凸部的4个侧面中的彼此相对的两个侧面所成的顶角具有比90°大的角度。
通过如此设为顶角比90°大的四棱锥形状，从而咬入到作为工件的合成树脂制片的凸部的侧面与合成树脂制片之间的粘附被抑制。因而，能够抑制工件在超声波接合后附着于工具的现象。
附图说明
图1是表示袋装电极的袋状隔板作为工件的一个例子的俯视图。
图2是表示超声波接合装置的概略的结构的说明图。
图3是表示隔板的层构造的剖视图。
图4是表示作为一实施例的超声波接合用工具的头的立体图。
图5是沿着图4的A-A线的剖视图。
图6是表示凸部中的一个的立体图。
图7是示意性地表示凸部对隔板进行接合的状态的剖视图。
图8是表示实施例的头和比较例的头的粘附力的特性的特性图。
具体实施方式
以下，对适用到层叠型电池单元的袋状隔板的接合所使用的超声波接合用工具的实施例作为本发明的一实施例进行说明。
图1表示作为工件的袋装电极。如在专利文献1中所公开那样，袋装电极是将两张片状隔板1在周缘处相互接合而成为袋状，并在两张片状隔板1之间夹入正极2而成的，通过与未图示的负极交替地层叠，构成所谓的电极层叠体。
片状隔板1分别被裁断成比正极2稍大的长方形，在周缘的多个部位，例如图示那样的共8个部位的接合部3处利用超声波接合进行相互接合。此外，正极2的集电体的一部分作为与未图示的电极引板连接的引板2a而从隔板1的一边延伸。
隔板1如在图3中表示截面构造那样具有4层构造，该4层构造从在成为袋状时处于外侧的面起依次具备聚丙烯层11、聚乙烯层12、聚丙烯层13、耐热层14。也就是说，具有多孔性的3个层11、12、13作为热塑性合成树脂层，且在一个表面设有耐热层14。耐热层14将例如陶瓷粒子与粘合剂一起向合成树脂层之上喷射而形成多孔性的陶瓷层。聚丙烯层11、13具有例如170℃左右的熔点，成为熔点比该聚丙烯层11、13相对较低的聚乙烯层12(具有例如140℃左右的熔点)层叠于两个聚丙烯层11、13之间而成的构造。
在将具有这样的4层构造的隔板1作为袋状隔板之际，以各耐热层14相互面对的方式重叠两张片状隔板1，如图2所示，使用超声波接合装置21而对周缘的接合部3分别进行接合。
超声波接合装置21具备：砧座22，其从下方支承工件(两张隔板1)；和变幅杆23，其与未图示的励振装置连结起来，在变幅杆23的顶端设有超声波接合用工具也就是头24。变幅杆23呈沿着大致水平方向延伸的圆棒状，被未图示的励振装置沿着该变幅杆23的长度方向(图的左右方向)励振。并且，在变幅杆23的成为振动的波腹的位置配置有与隔板1接触的成为实质上的加工部的头24。变幅杆23被未图示的加压机构以预定的载荷朝向砧座22加压。如此，超声波接合装置21一边在变幅杆23与砧座22之间对两张隔板1进行加压一边施加超声波振动，从而使两张隔板1的热塑性合成树脂层相互熔接。
如图4所示，头24呈与接合部3的大小相对应的长方形的板状。头24使用例如工具钢等而形成为与变幅杆23不同的零部件，并能够安装于变幅杆23来使用。或者，也可以作为变幅杆23的一部分而直接形成于变幅杆23。在图4的例子中，变幅杆23的振动方向成为沿着头24的宽度方向(与头24的长度方向正交的方向)的方向。
头24具备有规律地排列的多个凸部31。也如图6所示，各凸部31呈具有4个倾斜的侧面31a、31b、31c、31d和平坦的顶面31e的四棱锥形状。尤其是，在一实施例中，呈4个底边32a、32b、32c、32d(参照图6)构成正方形的正四棱锥形状(严密而言，呈顶部被顶面31e切掉而成的正四棱锥形状)。
另外，多个凸部31以各自的底边呈直线状排列的方式以恒定间隔有规律地排列。换言之，以在相邻的两个凸部31之间产生的V字形槽33呈直线状连续的方式排列有多个凸部31。此外，V字形槽33的底面33a(也就是说，在两个凸部31的底边之间存在的面)作为整体沿着一个平面。
而且，在图示例中，各凸部31的底边32a、32b、32c、32d相对于头24的长度方向以45°的角度倾斜。因而，由4个底边32a、32b、32c、32d形成的四边形(在图示例中，是正方形)的一个对角方向沿着变幅杆23的振动方向。
图5表示沿着图4的A-A线的截面。换言之，表示沿着相对于头24的长度方向呈45°的角度且通过凸部31的顶面31e的平面剖切头24而成的截面。如该图5所示，4个侧面31a、31b、31c、31d中的彼此相对的两个侧面(在图5中，侧面31a和侧面31c)所成的顶角α呈比90°大的角度。优选的是，上述顶角α处于110°～130°的范围内。在图示例中，顶角α是120°。
图示例的凸部31是4个侧面31a、31b、31c、31d呈相等的形状的正四棱锥，因此，剩余的两个侧面31b、31d所成的顶角也与图5所示的顶角α相等。
此外，在优选的一实施例中，顶面31e的一个边的长度是0.2mm。也就是说，实施例的凸部31的顶面31e具有0.2mm×0.2mm的大小，且彼此相对的两个侧面所成的顶角α具有120°的角度。
上述那样的结构的凸部31是通过在例如由工具钢等形成的板状的母材的表面对上述的V字形槽33进行磨削加工或切削加工而构成的。
图7示意性地表示在砧座22与具备上述那样的凸部31的头24之间对作为工件的两张片状隔板1进行超声波接合时的状态。在图示例中，砧座22呈平坦面。如前述那样一边以预定的载荷加压一边施加超声波振动，从而使头24的凸部31咬入两张隔板1中。由此，由陶瓷粒子构成的耐热层14被破坏，各隔板1的热塑性合成树脂层(聚丙烯层11、聚乙烯层12、聚丙烯层13)彼此可靠地熔接。
另一方面，凸部31咬入热塑性合成树脂层的结果，熔融后的热塑性合成树脂(聚乙烯或者聚丙烯)粘附于凸部31的侧面31a、31b、31c、31d，在超声波接合的完成后，在超声波接合装置21的变幅杆23上升时有可能工件保持附着到变幅杆23的状态被抬起。尤其是，熔点比最外层的聚丙烯层11的熔点低的聚乙烯层12的熔融树脂出来到聚丙烯层11的表面，易于附着于侧面31a、31b、31c、31d。而且，在超声波接合之际，一般而言，对作为工件的片状隔板1赋予张力，因此，若张力随着超声波接合的结束而被释放，则因张力而延长的隔板1要收缩而更易于附着于凸部31的侧面31a、31b、31c、31d。
针对这样的工件的粘附的问题，在上述实施例的头24中，凸部31的顶角α呈比90°大的角度(也就是说，钝角)，因此，超声波接合后的工件向凸部31的粘附被抑制。其理由之一在于，顶角α较大，因此，向热塑性合成树脂层的局部的咬入被抑制，并且熔点较低的聚乙烯层12的熔融树脂向聚丙烯层11的表面压出来的现象被抑制。进而，在片状隔板1的张力随着超声波接合的结束而被释放了时，凸部31的侧面31a、31b、31c、31d相对于隔板1要收缩的方向以比45°小的角度倾斜，因此，沿着与侧面31a、31b、31c、31d垂直的方向作用的分力变小，难以产生随着片状隔板1的收缩的向侧面31a、31b、31c、31d的粘附。
因而，在利用超声波接合装置21依次进行接合部3的超声波接合之际，工件附着于变幅杆23的现象被抑制，作业效率提高。
作为顶角α，优选如上述这样处于110°～130°的范围内。若比110°小，则抑制粘附的作用变弱。若比130°大，则凸部31向隔板的咬入变弱，破坏由陶瓷粒子构成的耐热层的作用易于变得不充分。
作为头24的更优选的第2实施例，也可以在上述的形状的凸部31的表面实施非粘接性涂敷。例如，在通过磨削或切削等机械加工形成的凸部31的表面实施喷丸而使作为各面31a～31e的边界的边缘倒圆，并且对各面31a～31e进行了研磨，在此基础上实施非粘接性涂敷。作为非粘接性涂敷，优选例如碳化钨系的涂敷、氮化铬系的涂敷。在一实施例中，以4～10μm的膜厚实施了以“BALINIT CROMA PLUS(注册商标)”这样的名称在商业上提供的基于物理蒸镀法的氮化铬系的涂敷。
通过如此实施喷丸和非粘接性涂敷，工件向凸部31的粘附被进一步减轻。
图8是针对顶角α是90°的比较例(无表面处理)、顶角α是120°的实施例(无表面处理)以及顶角α是120°且在表面实施了喷丸和氮化铬系的涂敷的第2实施例，汇总了工件随着超声波接合而向头24的粘附的特性的图表。横轴是由超声波接合装置21进行的接合加工时的振幅，一般而言以50％～70％左右的设定进行超声波接合。纵轴是对将由于超声波接合而粘附到头24的工件(隔板1)从头24剥离所需要的力进行测定，并将该力作为“粘附力”评价而成的。此外，比较例的凸部是使顶面的大小与实施例的顶面31e的大小相等、顶角α设为90°的正四棱锥形状的凸部。
如图8所示，与顶角α是90°的比较例相比较，在顶角α是120°的实施例中，粘附力降低，在实施了表面处理的第2实施例中，粘附力进一步降低。
以上，对本发明的一实施例进行了说明，但本发明并不限定于上述实施例，而能够进行各种变更。例如，作为隔板1，并不限于上述那样的4层构造的隔板，本发明适合于在1层或者多层热塑性合成树脂层的一个表面设有耐热层的隔板1的接合，除了袋装电极的形成以外，也适合于隔板1彼此的接合。而且，本发明也能够广泛地适用于不具备耐热层的一般的合成树脂制片的接合中。
另外，在上述实施例中，对将本发明适用到设置于超声波接合装置21的变幅杆23侧的工具也就是头24的例子进行了说明，但也能够将具有同样的凸部31的超声波接合用工具设置于砧座22侧。而且，也可在变幅杆23侧和砧座22侧这两侧设有凸部31。
超声波接合装置21的振动方向也可以是沿着呈长方形的头24的长度方向的方向。
另外，在上述实施例中，凸部31呈正四棱锥形状，但也可以设为4个底边所构成的四边形成为长方形或者菱形这样的四棱锥形状。在该情况下，需要4个侧面中的彼此相对的两个侧面所成的两个顶角均是比90°大的角度。

Claims (11)

1.一种超声波接合用工具，其用于将合成树脂制片重叠而接合的超声波接合装置的变幅杆侧或者砧座侧，并与上述合成树脂制片接触，其中，
该超声波接合用工具排列有多个凸部，该凸部呈具有平坦的顶面的四棱锥形状，
各凸部的4个侧面中的彼此相对的两个侧面所成的顶角处于110°～130°的范围内，
上述凸部以恒定间隔有规律地排列，并且在任何相邻的两个上述凸部之间形成呈直线状连续的槽。
2.根据权利要求1所述的超声波接合用工具，其中，
上述顶角是120°。
3.根据权利要求1或2所述的超声波接合用工具，其中，
上述凸部呈具有平坦的顶面的正四棱锥形状。
4.根据权利要求1或2所述的超声波接合用工具，其中，
该超声波接合用工具用于上述变幅杆侧，
由上述凸部的底边形成的四边形的一个对角方向沿着该变幅杆的振动方向。
5.根据权利要求1或2所述的超声波接合用工具，其中，
在至少上述凸部的表面实施非粘接性涂敷。
6.根据权利要求1或2所述的超声波接合用工具，其中，
作为工件的上述合成树脂制片在接合状态下从处于外侧的面起依次具备聚丙烯层、聚乙烯层、聚丙烯层、陶瓷耐热层。
7.根据权利要求6所述的超声波接合用工具，其中，
上述工件是电池单元的袋状隔板。
8.根据权利要求1或2所述的超声波接合用工具，其中，
所述变幅杆和所述砧座中的一者形成平坦面。
9.一种超声波接合方法，其中，
在该超声波接合方法中，
将权利要求1所记载的超声波接合用工具用于变幅杆侧或者砧座侧，
将包括具有聚乙烯层和聚丙烯层的热塑性合成树脂层以及陶瓷耐热层的两张合成树脂制片以上述陶瓷耐热层彼此面对的方式重叠，并一边进行加压一边施加超声波振动，
将上述陶瓷耐热层破坏并使上述热塑性合成树脂彼此熔接。
10.根据权利要求9所述的超声波接合方法，其中，
上述超声波接合用工具用于上述变幅杆侧，上述砧座具有与上述合成树脂制片接触的平坦面，
每个上述合成树脂制片具备上述聚丙烯层、上述聚乙烯层、另一上述聚丙烯层、上述陶瓷耐热层，
通过在上述变幅杆侧的上述超声波接合用工具与上述砧座之间对上述两张合成树脂制片进行加压并施加超声波振动，从而将上述陶瓷耐热层破坏，将上述两张合成树脂制片接合起来。
11.根据权利要求10所述的超声波接合方法，其中，
上述变幅杆以上述变幅杆的振动方向沿着由上述凸部的底边形成的四边形的一个对角方向的方式振动。
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US10625475B2 (en) 2020-04-21
US20200070431A1 (en) 2020-03-05
KR102186301B1 (ko) 2020-12-03
WO2018122964A1 (ja) 2018-07-05
KR20190085139A (ko) 2019-07-17

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